Vortex Inhibitor Pig for Full-Circumference Pipeline Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for applying treating liquids to the interior surfaces of pipelines, such as inhibitors and cleaning chemicals, fail to ensure adequate coverage of the upper interior portions, with limitations in gas and liquid flow through pipeline pigs and inefficient mixing and coating effects.
Innovation Solution
A pipeline pig design featuring a nozzle with a venturi and circumferential ports, a low-pressure plenum, and perforated sealing elements, which creates a vortex effect for improved distribution and coating of liquids across the entire interior surface by drawing in both liquid and vapor to achieve a 360° coating application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the dispersion method uses a single nozzle and limited bypass flow, then the device complexity is reduced, but the coating coverage and mixing effectiveness deteriorate
Solution Approach 1:
The single nozzle is segmented into multiple nozzles (first nozzle and second nozzle) positioned at different locations and angles. This segmentation allows the system to cover different areas of the pipeline interior simultaneously, achieving comprehensive 360-degree coating coverage without requiring an overly complex single-component system.
Solution Approach 2:
The nozzles are positioned at different angular orientations and spatial locations to create multi-dimensional spray coverage. The first nozzle sprays at a first angle while the second nozzle sprays at a second angle, transforming a one-dimensional linear spray into a three-dimensional omnidirectional coating pattern that covers the entire pipeline circumference.
2Reliability
If the pipeline pig limits bypass gas or liquid flow through the body, then the sealing and pushing capability is improved, but the dispersion and mixing effectiveness deteriorates
Solution Approach 1:
A bypass passage is introduced as an intermediary flow path that allows a controlled portion of the pressurized gas to flow through the pig body while the majority of the flow continues to push the pig forward. This intermediary pathway enables simultaneous achievement of reliable sealing (main flow path) and effective mixing (bypass flow path) without compromising either function.
Solution Approach 2:
The system changes the flow parameters by creating different flow rates and pressures through the main body versus the bypass passage. The bypass passage is designed to allow a specific proportion of gas flow (controlled parameter) to achieve optimal mixing and dispersion, while the main flow maintains sufficient pressure for reliable sealing and pig propulsion.
3Use of energy by moving object
If the nozzle discharge velocity is limited by differential pressure, then the energy consumption is reduced, but the coating application speed and coverage deteriorates
Solution Approach 1:
The coating application function is segmented across multiple nozzles rather than relying on a single high-velocity nozzle. Each nozzle operates at moderate discharge velocity (lower energy consumption), but the combined effect of multiple nozzles positioned at different locations achieves comprehensive and rapid coating coverage equivalent to or exceeding a single high-velocity nozzle.
Solution Approach 2:
The spray outputs from multiple nozzles are merged to create a comprehensive coating pattern. By combining the spray cones from the first nozzle and second nozzle, the system achieves full 360-degree coverage, merging the productivity of multiple lower-energy nozzles to match or exceed the performance of a single high-energy nozzle while consuming less total energy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances the distribution and coating efficiency of treating liquids across the pipeline interior, overcoming limitations in existing methods by allowing greater gas and liquid flow and improved mixing, ensuring comprehensive coverage of the pipeline walls.
Implementation Method 1
creates a vortex effect for improved distribution and coating of liquids across the entire interior surface
Implementation Method 2
draws in both liquid and vapor to achieve a 360° coating application
Implementation Method 3
low-pressure plenum... which creates a vortex effect for improved distribution and coating of liquids
Data Source
Figure 1
Figure 2~6
Figure 3
AI summary
A pipeline pig-that moves by pressurized gas flow and provides for distribution of treating liquid subsisting in a lower portion of a pipeline-having a longitudinally extending nozzle located at a forward end of the pig, an array of helical-shaped louvers located on the discharge side of the nozzle and arranged circumferentially, and two perforated sealing elements that create a cavity that serves as a low pressure plenum. The louvers create a vortex effect and the perforated sealing elements allow vapor and liquid in front of the pig to be drawn into the cavity and discharged through the ports and back into the discharge of the nozzle. In this manner, liquid subsisting at a bottom portion of the pipeline is dispersed to achieve a complete 360° coating application of the interior cylindrical wall of the pipeline.